Ecopaint RoDip. Quality through rotation!

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Oscar Evans
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1 Ecopaint RoDip Quality through rotation!

Ecopaint RoDip The process with the perfect turn The RoDip rotational painting system stands for the perfect interplay between plant and conveyor, and ensures efficient transport solutions for

This technology is successfully used worldwide and it is equally suited to pre-treatment (PT), cathodic electrocoating (EC) and body washing.

2 Ecopaint RoDip The process with the perfect turn The RoDip rotational painting system stands for the perfect interplay between plant and conveyor, and ensures efficient transport solutions for vehicle bodies through treatment lines. The rotation of the complete body optimizes the process of immersion, flooding and draining. This technology is successfully used worldwide and it is equally suited to pre-treatment (PT), cathodic electrocoating (EC) and body washing. RoDip can be used in the automotive and automotive supplier industry as well as in general industry. RoDip plants are shorter, therefore saving valuable building space. RoDip process technology is compelling because of its excellent corrosion protection and surface coating quality, along with attractive operating costs. RoDip Rotation for a decisive advantage: Dirt particles are flushed out of cavities No sedimentation on horizontal surfaces = no sanding Uniform coating even in the cavities Improved coating quality, as there are fewer runs and sags Savings potential for paint material and chemicals (less carry-over due to rotation and tilting of bodies) No bath contamination by conveyor equipment, no moving parts over the tank Smaller bath volumes (first filling, reduced energy costs) Environmentally friendly: less waste water, less use of chemicals and lower energy consumption Car body inside an empty RoDip EC tank 2

Ecopaint RoDip Two models to meet your specific needs RoDip M chain drive The main characteristic of the RoDip M variant is the chain drive, on both sides, which pulls the rotation carrier through

RoDip E electrical drive The RoDip E variant is characterized by its electrically driven transport unit on one side. The unit has a conveying drive and a separate drive for rotation.

RoDip M chain Selecting the right RoDip model Both variants can handle plant capacities of up to 80 units per hour.

3 Ecopaint RoDip Two models to meet your specific needs RoDip M chain drive The main characteristic of the RoDip M variant is the chain drive, on both sides, which pulls the rotation carrier through the process line. The RoDip M carrier is fitted with a lever that runs on fixed cams, thus allowing either a linear or rotary movement. RoDip E electrical drive The RoDip E variant is characterized by its electrically driven transport unit on one side. The unit has a conveying drive and a separate drive for rotation. The transport unit is positioned via a path measuring system. A WLAN signal is used to communicate with the controls. RoDip M chain Selecting the right RoDip model Both variants can handle plant capacities of up to 80 units per hour. RoDip E is recommended for capacities of up to 40 uph, as it is more economical for such applications. RoDip M is recommended for capacities of more than 40 uph. Both variants can be used across the whole capacity range. RoDip E rotating gears max Flexibility min RoDip E RoDip M Capacity uph RoDip M RoDip E Driving Robust drive chain on both sides adjacent to tank Electrically driven transport unit on one side Turning Rotation by v-cams Rotation through a separate drive Returning Horizontal return lines beneath the tanks Vertical return lines Fast return line up to 60 m/min Ecopaint RoDip For top quality and high profitability 3

Ecopaint RoDip Application advantages RoDip stands for quality and space savings RoDip Overhead conveyor Space saved with RoDip In comparison with conventional technologies, the dip tank for RoDip is

RoDip stands for compact construction Return lines for the RoDip M run beneath the plant. RoDip E return lines and rotation carrier drive equipment are arranged on one side of the plant.

thus a high degree of flexibility in adapting to existing building conditions.

4 Ecopaint RoDip Application advantages RoDip stands for quality and space savings RoDip Overhead conveyor Space saved with RoDip In comparison with conventional technologies, the dip tank for RoDip is considerably shorter as there is no need for inclined sections at its entrance and exit. With the rotational dip process, car bodies make a 360º turn as they pass through the dip tank. RoDip stands for compact construction Return lines for the RoDip M run beneath the plant. RoDip E return lines and rotation carrier drive equipment are arranged on one side of the plant. RoDip stands for more flexibility Single Loop in line VBH KTL Single loop in parallel VBH Separate loops in line VBH KTL Separate loops in parallel VBH RoDip offers more variety in layout options and thus a high degree of flexibility in adapting to existing building conditions. Existing PT/EC plants can be modified to RoDip E, without changing the process an affordable and easy way to change to RoDip technology. KTL only RoDip E KTL RoDip stands for uniform coating RoDip produces a uniform high quality coating surface even in hard to reach cavities. Cavity film thickness measurements after RoDip rotation 7µm are deducted for the zinc film giving the following results: Average film thickness = =15.8µ Minimum film thickness = =13.0µ Maximum film thickness = = 19µ 4

In addition to the process, quality and plant design advantages already described, RoDip also

times Entrance and exit modules independent of body width Standard components: shaft lifting

rotating front view Conveyor equipment adjacent to the plant Maintenance walkways easy access

Conveyor equipment simple return Fold-away carrier shaft reduction in plant height

equipment Compact and simple technology Shorter system less space required Fewer moving parts

5 In addition to the process, quality and plant design advantages already described, RoDip also offers customers the following benefits: Modular construction accelerated project realization times Entrance and exit modules independent of body width Standard components: shaft lifting mechanisms, conveyor tracks and transport units Plant height can be easily adjusted Body rotating front view Conveyor equipment adjacent to the plant Maintenance walkways easy access No moving parts in the process tanks no contamination Reduced tunnel area less heat loss Conveyor equipment simple return Fold-away carrier shaft reduction in plant height Minimization of space required for carrier return Carrier shaft Better access to conveyor equipment Compact and simple technology Shorter system less space required Fewer moving parts Simple tunnel seal less wear less heat loss Body rotating side view Ecopaint RoDip For top quality and high profitability 5

Lower cost per unit with RoDip Index 40 35 30 25 How RoDip saves money: Plant and building investment: Much smaller installation with RoDip: layout flexibility and modular system lower the costs by

5 0 Building investment Material Personnel Maintenance Energy Total Conventional 35.0 28.6 22.8 8.0 5.5 100.0 With RoDip 32.2 27.4 13.3 7.8 3.5 84.2 Savings in % 8.1 4.4 41.8 2.8 35.4 15.

6 Lower cost per unit with RoDip Index How RoDip saves money: Plant and building investment: Much smaller installation with RoDip: layout flexibility and modular system lower the costs by about 8% Conventional With RoDip Material costs in PT and EC can be reduced through smaller dip tanks, better outflow and less carry-over more than 4%. 5 0 Building investment Material Personnel Maintenance Energy Total Conventional With RoDip Savings in % Personnel costs: Less dirt, runs and sags reducing rework and sanding significantly. Clear cost savings of about 42%. Maintenance costs: Nearly 3% less through simple and robust technology with low maintenance, straight chain guidance and good accessibility. RoDip stands for significant cost per unit savings due to lower expenses for building investment, material, personnel, maintenance and energy. Energy savings: Around 35% lower costs thanks to better circulation and heating efficiency, based on smaller bath volumes and less (waste) water. If you create a sample calculation based on a European plant producing mid-sized car bodies per year with a conventional PT/EC coating system, the use of RoDip saves nearly 16% per car. 6

Worldwide references RoDip automotive installations Manufacturer Location Vehicle Capacity SOP [u/h] VW Puebla, Mexico passenger cars 34.

Oktavia 34 2008 Tata Kolkatta, India passenger cars 68 2008 Pemsa Saltillo, Mexico pick up load boxes 30 2008 PIDF Saveh, Iran passenger cars 12 2008 TAM Khorasan, Iran PARS, Peugeot 405 28 2007 JAC

7 Worldwide references RoDip automotive installations Manufacturer Location Vehicle Capacity SOP [u/h] VW Puebla, Mexico passenger cars BMW Spartanburg, SC, USA BMW X Changan Chongqing, China passenger cars 54, Honda Swindon, UK passenger cars VW Kaluga, Russia Golf, Oktavia VW Pune, India Golf, Oktavia Tata Kolkatta, India passenger cars Pemsa Saltillo, Mexico pick up load boxes PIDF Saveh, Iran passenger cars TAM Khorasan, Iran PARS, Peugeot JAC Hefei, China passenger cars KIA Zilina, Slovakia passenger cars Daimler Ludwigsfelde, Germany NCV3, VWLT3 (large vans) Karmann Osnabrück, Germany passenger cars Hyundai Montgomery, AL, USA Sonata Ferrari Maranello, Italy Ferrari, Maserati SAIC Chery Wuhu, China passenger cars Audi Ingolstadt, Germany A3, A4, TT 2x SVW Shanghai, China Polo VW Wolfsburg, Germany Touran BMW Munich, Germany BMW BMW Dingolfing, Germany BMW 5,7, RR 2x AMG South Bend, IN, USA Hummer H RoDip commercial vehicle installations Manufacturer Location Vehicle Capacity SOP [u/h] Mahindra Chakan, India trucks Daimler Wörth, Germany truck cabs Renault Blainville, France trucks Navistar Monterrey, Mexico trucks Volvo Umea, Sweden trucks Volvo Curitiba, Brazil trucks GM Bogota, Columbia cars, trucks Volvo Dublin, VA, USA trucks Ecopaint RoDip For top quality and high profitability 7

Ecopaint RoDip Quality through rotation Your competitive edge with

and robust More than 14 million vehicle bodies already RoDipped

rotation Paint and Final Assembly Systems www.durr.

All outlined values and savings are based on standard layouts and our

Actual values and savings are dependent on project specific layouts,

8 Ecopaint RoDip Quality through rotation Your competitive edge with Dürr: Mechanical and electrical versions available Simple, flexible and robust More than 14 million vehicle bodies already RoDipped Reduction in cost per unit Increased quality increase due to 360 rotation Paint and Final Assembly Systems We reserve the right to make modifications! All outlined values and savings are based on standard layouts and our experience and do not constitute contractual obligations of any kind. Actual values and savings are dependent on project specific layouts, technical specifications and other related determining factors and have to be individually established. Dürr 2009 Stuttgart

Ecopaint RoDip4. Quality through rotation!

Ecopaint RoDip4. Quality through rotation! Ecopaint RoDip4 Quality through rotation! Ecopaint RoDip4 Rotation for that decisive advantage The process with the perfect turn! RoDip4 is the next step in systematic further development of our established